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Advances in Intelligent Robots and Precision Machining

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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Robotics and Automation".

Deadline for manuscript submissions: closed (30 July 2023) | Viewed by 21192

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Special Issue Editors

Dr. Zhongchen Cao

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Guest Editor

School of Mechanical Engineering, Tianjin University, Tianjin 300072, China
Interests: ultra-precision machining technology; intelligent manufacturing and industrial robotics; abrasive machining technology; innovative hybrid manufacturing processes for difficult-to-machine materials; materials science/workpiece surface integrity analysis; modelling, simulation, and optimization of manufacturing processes
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Dr. Haitao Liu

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Guest Editor

Industrial Robotics and Application Laboratory, Tianjin University, Tianjin 300072, China
Interests: robotics and application; mechanisms and robotics

Dr. Mingyu Liu

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Guest Editor

Manufacturing Metrology Team, Faculty of Engineering, University of Nottingham, Nottingham NG8 1BB, UK
Interests: manufacturing metrology; optical measurement; machine learning

Special Issue Information

Dear Colleagues,

The key issues to the combination of precision machining technology and intelligent robots are to ensure the controllability/flexibility of the manufacturing process and the reliability of the machined parts. Due to recent advancements in robotic, control and manufacturing, this technology enables the manufacturing process to be flexible, efficient, convenient, and even able to further improve surface accuracy and integrity. Therefore, research focusing on precision (and ultra-precision) machining technology using intelligent robots is essential for industrial development and upgrading industrial structures. New machining processes and quantification of the materials microscopic removal mechanism have led to the development of novel ultra-precision machining theories, which reveal the laws of material removal and destruction under different machining processes, and provide error suppression/compensation methods in different spatial frequency bands. As a result, to reveal the material removal mechanism and develop a better understanding of robot-controlled ultraprecision machining technology, a study of detailed and reliable quantification is necessary. Additionally, the emergence of advanced manufacturing equipment, monitoring techniques for manufacturing processes, and phenomena of processed materials also provide insight into intelligent robot-controlled ultra-precision machining technology.

We are pleased to invite you to contribute to a Special Issue of Applied Sciences on “Advances in Intelligent Robot and Precision Machining”. This Special Issue aims to focus on intelligent robot-assisted precision machining technology and its applications.

In this Special Issue, original research articles and reviews are welcome. Research areas may include (but are not limited to) the following:

Robotics, mechatronics, and manufacturing automation;
Precision engineering, inspection, measurement, and metrology;
Manufacturing planning, optimization, and simulation;
Computer-integrated manufacturing systems;
Smart manufacturing;
Human–robot collaborative manufacturing;
Adaptive and sustainable manufacturing;
Micro/nanofabrication and manufacturing;
Computer-aided manufaeturing;
Ultraprecision machining technology.

We look forward to receiving your contributions.

Dr. Zhongchen Cao
Dr. Haitao Liu
Dr. Mingyu Liu
Guest Editors

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Keywords

robotics
computer-integrated manufacturing
ultraprecision machining
measurement

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Published Papers (10 papers)

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Research

21 pages, 4056 KiB

Open AccessArticle

Development of Pitch Cycle-Based Iterative Learning Contour Control for Thread Milling Operations in CNC Machine Tools

by Syh-Shiuh Yeh and Wei-Jia Jiang

Appl. Sci. 2023, 13(11), 6447; https://doi.org/10.3390/app13116447 - 25 May 2023

Cited by 4 | Viewed by 1507

Abstract

The helical contour motion accuracy of feed drive axes is important for thread milling operations in computer numerical control (CNC) machine tools. However, the motion dynamics and external disturbances significantly affect the contour motion results, while the feed drive axes perform helical motions in thread milling operations. Although existing iterative learning contour control (ILCC) methods can improve contour motion accuracy, the problems of data recording and processing on memory usage and computational burden in control systems, wasted materials, and increased costs in thread manufacturing still limit the practical applications of ILCC. Therefore, considering the similar motion dynamics and external disturbances of the feed drive axes during the pitch cycle motions of a helical path, this study developed a pitch cycle-based iterative learning contour control (PCB-ILCC) method to address the control system and thread manufacturing problems caused by the use of ILCC. For PCB-ILCC, this study adopted contour error vector estimation by referring to the interpolated positions on the pitch cycle of the helical path to simplify the computational complexity and designed the ILCC using the cycle learning method to easily implement the ILCC structure. Thus, this study developed a permanent magnet synchronous motor (PMSM) driving control utilizing the robust control method to mitigate the problems of motion dynamics and external disturbances on the feed drive axes. Thread milling experiments performed on a five-axis CNC machining center demonstrated the feasibility of the PCB-ILCC and validated that it can significantly improve the helical contour motion accuracy of the feed drive axes and achieve an 80% contour error reduction rate in comparison with the proportional–proportional–integral control, which is extensively used in commercialized PMSM drivers and CNC controllers. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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13 pages, 6031 KiB

Open AccessArticle

Effect of Robot Motion Accuracy on Surface Form during Computer-Controlled Optical Surfacing Process

by Yong-Tong Chen, Mingyu Liu and Zhong-Chen Cao

Appl. Sci. 2022, 12(23), 12301; https://doi.org/10.3390/app122312301 - 1 Dec 2022

Cited by 2 | Viewed by 1671

Abstract

Nowadays, large-aperture optical components are increasingly used in high-power laser systems, remote-sensing satellites, and space-based astronomical telescopes. Fabricating these surfaces with submicron-scale shape accuracy and a nanoscale surface finish has been a great challenge for the optical industry, especially for hard and difficult-to-machine materials. Thus, to achieve the high-efficiency and high-precision polishing of large-aperture aspherical optical parts, this study combined robotic machining technology with computer-controlled optical surfacing (CCOS) technology and investigated the effect of robot motion accuracy on the surface topography of workpieces during polishing. First, a material removal model considering the normal error of the polishing tool was developed based on contact mechanics, kinematic theory, and the abrasion mechanism. Next, in combination with the polishing trajectory, the surface morphology and form accuracy after polishing were predicted under different normal-error conditions. Then, preliminary experiments were conducted to verify the model. The experimental data agreed with the simulation results, showing that as the normal error increased from 0° to 0.5° and 1°, the peak-to-valley (PV) values of the surface profile of the optical element decreased from 5.42, 5.28, and 4.68 μm to 3.97, 4.09, and 4.43 μm, respectively. The corresponding convergence rates were 26.8%, 22.5%, and 5.3%. The root mean square (RMS) values decreased from 0.754, 0.895, and 0.678 μm to 0.593, 0.620, and 0.583 μm, with corresponding convergence rates of 21.4%, 30.7% and 14.0%, respectively. Moreover, a higher motion accuracy enabled the polishing robot to reduce the mid- and high-frequency errors of the optical element. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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8 pages, 3360 KiB

Open AccessArticle

An On-Chip Silicon Photonics Thermometer with Milli-Kelvin Resolution

by Jin Wang, Yijie Pan, Jianxin Gao, Cheng Zhang, Zhier Qu, Tongtong Xu, Yang Shen and Jifeng Qu

Appl. Sci. 2022, 12(8), 3713; https://doi.org/10.3390/app12083713 - 7 Apr 2022

Cited by 8 | Viewed by 2059

Abstract

Photonic-based thermometers have been attracting intense research interest as a potential alternative to traditional electrical thermometers due to their physical and chemical stability and immunity to electromagnetic interference. However, due to the high requirements for the stability of the laser source, the existing studies on resolution are only theoretical predictions and do not include real-measured results. In this paper, we report on the fabrication and characterization of an on-chip silicon whispering-gallery-mode (WGM) ring resonator thermometer. The strip grating and the ring structure were fabricated on the silicon-on-insulator (SOI) substrate by two-step etching. The quality-factor (Q-factor), temperature sensitivity, and measurement range of the packaged device were 21,400, 42 pm/K, and 150 K, respectively. The real-measured temperature resolution of 2.9 mK was achieved by virtue of the power and polarization stabilization of the laser source. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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11 pages, 3045 KiB

Open AccessArticle

Investigation of an Influence Function Model as a Self-Rotating Wheel Polishing Tool and Its Application in High-Precision Optical Fabrication

by Yongsheng Yao, Qixin Li, Jiaoteng Ding, Yongjie Wang, Zhen Ma and Xuewu Fan

Appl. Sci. 2022, 12(7), 3296; https://doi.org/10.3390/app12073296 - 24 Mar 2022

Cited by 5 | Viewed by 2173

Abstract

A new and patented polishing tool (ZL2020102387137) called a Self-rotating Wheel Polishing Tool (SWPT) was built, and its tool influence function (TIF) was investigated in this study. The polishing wheel is an innovative two-layer structure: a rigid hub inside and a flexible polishing pad outside. By using finite element analysis, the dynamic contact characteristics between the polishing wheel and the workpiece were studied, and the theoretical TIF was modeled. Due to the influence of friction resistance, the TIF is not circular, but oval. We then ran material removal experiment, and it was found that the experimental TIF and the theoretical TIF are very close and both are close to the Gaussian shape. Finally, optical fabrication was performed. After four times of about 3 h fabrication, the form error converged from PV-1.434λ (λ = 632 nm), RMS-0.308λ to PV-0.144λ, RMS-0.009λ, and PV and RMS converged by 90% and 97%, respectively. The form accuracy achieved the expected target of RMS-0.02λ, which proves that the SWPT has the characteristics of high convergence rate and high fabrication accuracy. The SWPT has a broad application prospect in the field of high-precision optical fabrication. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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14 pages, 5140 KiB

Open AccessArticle

Autostereoscopic-Raman Spectrometry-Based Three-Dimensional Metrology System for Measurements, Tracking and Identification in a Volume

by Jingfan Wang, Xing Zhao, Da Li, Ya Wen, Weihao Wang, Bin Wang, Xiaoxuan Xu, Hua Bai and Weiwei Liu

Appl. Sci. 2022, 12(6), 3111; https://doi.org/10.3390/app12063111 - 18 Mar 2022

Cited by 3 | Viewed by 1668

Abstract

Three-dimensional compound measurement within a volume of interest is of great importance in industrial manufacturing and the biomedical field. However, there is no current method that can simultaneously perform spatial localization and 3D measurement in a non-scanning manner as well as the identification of material in a volume. In this paper, an Autostereoscopic-Raman Spectrometry-based (ARS) three-dimensional measurement system is proposed. The target object in a large depth range is initially positioned by the autostereoscopic 3D measurement method, and then the accurate position information is cross-checked and obtained by combining the spectral signal. Meanwhile, the spectral signal at the precise excitation position guided by the autostereoscopic signal also carries the material composition information. In order to verify the proposed ARS method, an associated measurement system was developed, and experimental studies of detecting various fibers of different depths in multi-layer glass structure were conducted. The spatial locations and dimensional information of multiple different targets can be measured in a volume, and their material can also be identified at the same time. The average error between the calculated position processed by the ARS system and the actual spatial position is within sub-micron levels, and the success rate of spectrum acquisition reaches 98%. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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12 pages, 2697 KiB

Open AccessArticle

A Fiducial-Aided Reconfigurable Artefact for the Estimation of Volumetric Errors of Multi-Axis Ultra-Precision Machine Tools

by Shixiang Wang, Chifai Cheung and Lingbao Kong

Appl. Sci. 2022, 12(4), 1824; https://doi.org/10.3390/app12041824 - 10 Feb 2022

Cited by 1 | Viewed by 1750

Abstract

In this paper, a fiducial-aided reconfigurable artefact is presented for estimating volumetric errors of multi-axis machine tools. The artefact makes use of an adjustable number of standard balls as fiducials to build a 3D artefact which has been calibrated on a coordinate measuring machine (CMM). This 3D artefact demonstrates its reconfigurability in its number of fiducials and their locations according to the characteristics of workpieces and machine tools. The developed kinematics of the machine tool were employed to identify the volumetric errors occupied by the workpiece in the working space by comparing the information acquired by on-machine metrology with that acquired by the CMM. Experimental studies are conducted on a five-axis ultra-precision machine tool. A developed 3D artefact composed of five standard spheres is measured by the integrated on-machine measurement system. Factors including the gravity effect and measurement repeatability are also examined in order to optimize the geometry of the artefact. The results show that the developed 3D artefact is able to provide information about the working space occupied by the workpiece. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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9 pages, 16144 KiB

Open AccessArticle

The Microfabricated Alkali Vapor Cell with High Hermeticity for Chip-Scale Atomic Clock

by Shuo Jia, Zhiyuan Jiang, Binbin Jiao, Xiaochi Liu, Yijie Pan, Zhenfei Song and Jifeng Qu

Appl. Sci. 2022, 12(1), 436; https://doi.org/10.3390/app12010436 - 3 Jan 2022

Cited by 11 | Viewed by 2616

Abstract

Herein, a microfabricated millimeter-level vapor alkali cell with a high hermeticity is fabricated through a wet etching and single-chip anodic bonding process. The vapor cell, containing Rb and N₂, was investigated in a coherent population trapping (CPT) setup for the application of a chip-scale atomic clock (CSAC). The contrast of CPT resonance is up to 1.1% within the only 1 mm length of light interacting with atom. The effects of some critical external parameters on the CPT resonance, such as laser intensity, cell temperature, and buffer gas pressure, are thoroughly studied and optimized. The improved microfabricated vapor cell also exhibited great potential for other chip-scale atomic devices. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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17 pages, 5708 KiB

Open AccessArticle

Microstructure Formation and Mechanical Properties of Multi-Phase Coating by Thermos Plasma Nitriding of Gradient Cu-Ti Films on C61900 Cu Alloy

by Yandan Zhu, Mufu Yan and Quanli Zhang

Appl. Sci. 2021, 11(22), 10843; https://doi.org/10.3390/app112210843 - 17 Nov 2021

Viewed by 1667

Abstract

To improve the processing efficiency and the surface properties of C61900 Cu alloy, a gradient Cu-Ti film with a Ti/Cu atom ratio of 7:1, 7:4, and 1:2 was pre-fabricated by the unbalanced magnetron sputtering process and then nitrided by thermos plasma nitriding. The phase structure, elemental composition, and morphology of the modified surface were characterized, and the mechanical properties, including the wear resistance and adhesion properties, were examined. Combining calculation by the first principle method with thermodynamic analysis, the microstructural formation and phase composition of the Cu-Ti-N system were investigated to reveal the mechanism of improved wear resistance, which indicated the possible formation of various Cu-Ti intermetallics and Ti-N compounds. The Al in the C61900 Cu substrate also participated in the generation of the AlCu₂Ti compound, which is a ductile phase with good hardness and elastic modulus. Based on the results of a mechanical properties test, it was concluded that an optimized layer structure for the multi-phase coating should include Ti-N compounds as the surface layer and Cu-Ti intermetallics as the intermediate layer. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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13 pages, 1929 KiB

Open AccessArticle

Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

by Yucheng Li, Xu Zhang and Cui Wang

Appl. Sci. 2021, 11(22), 10737; https://doi.org/10.3390/app112210737 - 14 Nov 2021

Cited by 3 | Viewed by 1877

Abstract

The friction behavior in the tool-chip interface is an essential issue in aluminum matrix composite material (AMCM) turning operations. Compared with conventional cutting, the elliptical vibration (EVC) cutting AMCM has attractive advantages, such as low friction, small cutting forces, etc. However, the friction mechanism of the EVC cutting AMCM is still inadequate, especially the model for cutting forces analyzing and predicting, which hinders the application of EVC in the processing of AMCM. In this paper, a cutting force prediction model for EVC cutting SiCp/Al is established, which is based on the three-phase friction (TPF) theory. The friction components are evaluated and predicted at the tool-chip interface (TCI), tool-particle interface (TPI) and tool-matrix (TMI), respectively. In addition, the tool-chip contact length and SiC particle volume fraction were defined strictly and the coefficient of friction was predicted. Based on the Johnson-Cook constitutive model, the experiment was conducted on SiCp/Al. The cutting speed and tool-chip contact length were used as input parameters of the friction model, and the dynamic changes of cutting force and stress distribution were analyzed. The results shown that when cutting speed reaches 574 m/min, the tool-chip contact length decreases to 0.378 mm. When the cutting speed exceeds 658 m/min, the cutting force decreases to a minimum of 214.9 N and remains stable. In addition, compared with conventional cutting, the proposed prediction model can effectively reduce the cutting force. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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21 pages, 39117 KiB

Open AccessArticle

Modeling and Compensation of Motion Errors for 6-DOF Robotic Manipulators

by Xuan Huang, Lingbao Kong and Guangxi Dong

Appl. Sci. 2021, 11(21), 10100; https://doi.org/10.3390/app112110100 - 28 Oct 2021

Cited by 2 | Viewed by 2671

Abstract

Six degree-of-freedom (6-DOF) robotic manipulators have been increasingly adopted in various applications in industries due to various advantages, such as large operation space, more degrees of freedom, low cost, easy placement, and convenient programming. However, the robotic manipulator has the problem of insufficient stiffness due to the series structures, which will cause motion errors of the manipulator end. In this paper, taking a 6-DOF robotic manipulator as an example, forward and inverse kinematics models are established, and a new modeling method for the joint angle and space stiffness of the end of the manipulator is proposed, which can establish the composite stiffness model of joint link stiffness and joint stiffness. An error compensation model is subsequently established. The experimental results indicate that the proposed error compensation method can effectively reduce the end motion error of the robotic manipulator, and hence, the working performance and accuracy of the manipulator can be improved. The proposed research is helpful for extending the application of robotic manipulators in precision machining and measurement. Full article

(This article belongs to the Special Issue Advances in Intelligent Robots and Precision Machining)

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